Swaged braided catheter and method of fabrication

Abstract

A swaged braided catheter ( 30 ) for use in various medical procedures is provided. The swaged braided catheter includes a tubular braid ( 32 ) formed from a plurality of braided wire members ( 38 ). A plurality of intersections ( 40 ) is formed by the braided wire members. The intersections are compressed defining a plurality of flattened regions along the tubular braid. The intersections have a first thickness (d 1 ) before being compressed and a reduced second thickness (t 2 ) after being compressed. The flattened regions with the reduced second thickness provide the swaged braided catheter with a reduced cross-sectional profile, and reduced catheter recoil.

The invention claimed is: 
     
       1. A catheter comprising:
 a tubular braid having a proximal end and a distal end and, the tubular braid comprising a plurality of wire members having a first portion having a round cross-section with a first diameter, the wire members being braided together to define the tubular braid, a plurality of intersections being formed by braiding of the wire members, wherein at the intersections the wire members are compressed to a non-round cross-section defining a plurality of flattened regions along the tubular braid, the wire members having a thickness at the flattened regions which is less than the first diameter, each flattened region being located between two first portions along a length of a wire member; 
 an inner liner positioned coaxially within and in contact with the tubular braid, the inner liner defining a lumen of the catheter formed through the proximal and distal ends of the tubular braid; and 
 an outer sleeve positioned coaxially about and in contact with the tubular braid. 
 
     
     
       2. The catheter of  claim 1 , wherein the intersections of the tubular braid have a first thickness before the intersections are compressed and a second thickness after the intersections are compressed, wherein the second thickness is less than the first thickness. 
     
     
       3. The catheter of  claim 2 , wherein the second thickness is approximately equal to one half of the first thickness. 
     
     
       4. The catheter of  claim 2 , wherein the catheter has a wall thickness dependent upon the second thickness of the flattened regions, a third thickness of the inner liner, and a fourth thickness of the outer sleeve. 
     
     
       5. The catheter of  claim 2 , wherein the first thickness is equal to two times the first diameter. 
     
     
       6. The catheter of  claim 1 , wherein the wire members are formed from one of stainless steel, tungsten, gold, titanium, silver, copper, platinum, palladium, iridium, ELGILOY nickel-cobalt alloys, cobalt-chrome alloys, molybdenum tungsten alloys, tantalum alloys, titanium alloys, and a mixture thereof. 
     
     
       7. The catheter of  claim 1 , wherein the first diameter is about 0.0020 inches. 
     
     
       8. The catheter of  claim 1 , wherein the first diameter is between about 0.0010 inches and about 0.0050 inches. 
     
     
       9. The catheter of  claim 1 , wherein the flattened regions are created by swaging. 
     
     
       10. A catheter comprising:
 a tubular braid having a proximal end and a distal end and, the tubular braid comprising a plurality of wire members having a first portion having a round cross-section with a first diameter, the wire members being braided together to define the tubular braid, a plurality of intersections being formed by braiding of the wire members, wherein at the intersections the wire members are compressed to a non-round cross-section defining a plurality of flattened regions of the wire members along the tubular braid, each flattened region being located between two first portions along a length of a wire member.